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IP Notes > Red Seal > Flashcards

Red Seal Flashcards

1
Q

Milling feed rate is in

A

inches per minute

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2
Q

Band saw feed rates for structural steel, piping, tubing

A

in square inches per minute
Structural steel - reduce by 25%
Piping - reduce by 50%
Tubing - reduce by 65%

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3
Q

Twist drill helix angle for soft materials such as aluminum, magnesium, zinc

A

High helix 40 degrees

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4
Q

Which milling produces the best surface finish

A

climb milling

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5
Q

Curved drag lines with slag buildup on the bottom when cutting with a torch indicates what

A

travel speed too fast

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6
Q

Amount of stickout for MIG welding

A

3/8”

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7
Q

What welding cable is bigger, 1/0 or #2

A

1/0 is bigger, use small cable as the whip for better rod manipulation

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8
Q

Most used flame for oxy-acetylene welding mild steel

A

neutral

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9
Q

GTAW electrode point taper length

A

2 to 2.5 times the diameter of electrode

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10
Q

Whats best for welding copper and aluminum

A

GTAW

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11
Q

Best flame for fusion welding

A

Neutral

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12
Q

Which oxy-acetylene tank do you turn off first

A

Close oxygen valve first, bleed oxygen line, close torch valve. Repeat for acetylene

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13
Q

What is the primary risk welding outdoors in windy conditions

A

porosity

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14
Q

Which SMAW power configurations offers the most penetration

A

DCEP (DC Electrode Positive, DC Reverse Polarity)
AC = Medium penetration
Straight polarity = Least penetration

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15
Q

Method used to join dissimilar metals together

A

brazing

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16
Q

What process cuts both ferrous and non-ferrous metals

A

plasma arc cutting

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17
Q

If a piece of steel cut by a torch has a rough edge with large amounts of slag on the bottom what is the cause

A

cutting tip is dirty

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18
Q

What kind of cutting tip is designed to cut close to a surface without damaging it

A

rivet/bulkhead tip

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19
Q

Hardhats need to be replaced how often

A

Every 5 years

Liner every year

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20
Q

What safety device is built into a acetylene cylinder

A

fusible plug

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21
Q

Automatic level formula

A

distance = (upper reading - lower reading) x 100

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22
Q

Most accurate tool to layout number parallel lines on a workpiece

A

Height gauge on a surface plate

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23
Q

Best direct measuring device for a bore diameter

A

inside micrometer

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24
Q

prick punch angle

A

30-60 degrees

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25
Q

Most accurate way of measuring shaft OD

A

outside micrometer

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26
Q

type of transfer measuring tool for bore diameters

A

telescoping gauge

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27
Q

tool used to find the centre of a shaft

A

centering head with scribe

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28
Q

thread pitch of a imperial micrometer

A

0.025”

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29
Q

What tool can aid in the production of angled lines

A

Trammel points using ARC method

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30
Q

How to calibrate 2”-3” outside micrometer

A

Clean anvil and spindle faces, use a 2 inch gage block or standard and check if it lines up to the 2 inch line

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31
Q

first step when setting up to use an optical level

A

set and level tripod

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32
Q

centre punch angle

A

90 degrees

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33
Q

most water resistant grease

A

lithium

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34
Q

which band saw blade set cuts the fastest

A

straight/alternate set (leaves rough cut)
wavy set for thin material like piping
raker set for smoothest cut

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35
Q

reamer used for keyed or slotted hole

A

spiral

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36
Q

two ways to cut material when milling

A

conventional and climb

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37
Q

When should you not increase cutting speed

A

hard materials

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38
Q

anti-foam additive in oils

A

silicone

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39
Q

brown and sharpe milling arbor taper

A

1/2” per foot

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40
Q

dowel pin taper

A

1/4” per foot

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41
Q

carbon content of 4140

A

0.40%

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42
Q

When cutting without cutting fluid on a bandsaw how much should you reduce cutting speed

A

40-50%

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43
Q

How is the angle of a cut adjusted on a vertical band saw

A

the work table is adjusted

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44
Q

Steels contain less than _% iron

A

2%

over 2% is called iron

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45
Q

grease used in cold environments

A

naptha

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46
Q

feed speed when using reamers

A

1/2 twist drill speed rpm, 2 times the feed

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47
Q

For steel to harden it must have a minimum carbon content of ___%

A

0.20%

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48
Q

which lathe dog engages the drive plate directly

A

bent tail dog

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49
Q

cutting speed formula

A

rpm = cutting speed x 4 / diameter of cutting tool

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50
Q

this relieves internal stresses and brittleness created by the hardening process

A

tempering

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51
Q

this process makes a hardened workpiece soft and machinable again

A

annealing

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52
Q

thread angle of a metric thread

A

60 degrees

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53
Q

standard helix drill angle

A

30 degrees

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54
Q

When should EP with sulfur not be used

A

brass and bronze components

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55
Q

this is the process of removing strain and irregular grain structure from a piece of steel

A

normalizing

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56
Q

thread designed to take high axial loads in one direction

A

buttress

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57
Q

the ability for a material to return to it’s original shape after being deformed

A

elasticity

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58
Q

thermal expansion formula

A

0.0000063 x temp change x size of workpiece

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59
Q

the process where a steel is heated up until it changes to austenite then quenched to form martensite

A

hardening

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60
Q

what should be done to the drill when drilling brass

A

slightly hone the cutting edge to reduce rake angle to zero

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61
Q

the ability of a metal to resist penetration and plastic deformation

A

hardness

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62
Q

the ability of a material to be stretched permanently without breaking

A

ductility

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63
Q

the ability of metal to withstand shock and impact without breaking or shattering

A

toughness

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64
Q

the ability of a metal to withstand pull without breaking

A

tensile strength

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65
Q

the ease you can cut and shape a metal

A

machinability

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66
Q

Single vertical hitch formula

A

SWL = Weight x (H/L) x 3

** when all 3 legs are not equal use the longest leg length**

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67
Q

Basket hitch formula

A

Basket = Weight x Number of legs x Sin(angle)

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68
Q

Smallest lift angle on a shouldered bolt

A

45 degrees

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69
Q

these allow chain sling legs to be adjusted for positioning of the lifting hook over the centre of gravity

A

load leveler

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70
Q

How to measure a wire rope

A

at it’s widest point, which is across the crowns. Measure 3 positions on a six-strand rope, 4 positions on a eight strand rope

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71
Q

what kind of steel is wire rope usually made of

A

plow steel

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72
Q

what type of knot ties two ropes of different diameter together

A

sheet bend

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73
Q

Rigging chain size is determined by

A

the link diameter, measure the non welded side with vernier calculator

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74
Q

What is an anchor (Dee) shackle for

A

lifting from many different angles

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75
Q

Chain shackles are used for

A

inline lifts

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76
Q

at what angle does each sling take the full weight of the load

A

30 degrees

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77
Q

what type of splice should should hoisting slings use

A

flemish eye splice

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78
Q

sling to use where loads are abrasive or hot

A

wire mesh sling

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79
Q

nylon sling SWL rule

A

1600lbs per inch

ex 2 inch sling = 3200lbs SWL

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80
Q

How to calculate the mechanical advantage of a rope block pulley

A

add up the lines not directly connected to the load or being pulled

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81
Q

what does a headache ball do

A

connects to the end of a crane wire rope to keep the line taught

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82
Q

formula for a 2 leg bridle hitch SWL

A

(H/L) x SWL = reduced SWL of each sling

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83
Q

replace running ropes when

A
  • six or more broken wires in one lay

- 3 or more broken wires in one strand in one lay

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84
Q

replace standing ropes when

A
  • three or more broken wires in one lay

- breaks near sockets or splices

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85
Q

minimum tapped hole depth for eye bolts

A

1.5 times nominal bolt diameter

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86
Q

destroy shackled when the crown or pin is worn by more than __%

A

10%

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87
Q

crosby clips are __% of the strength of the rope

A

80%

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88
Q

crosby clip formulas

A 
# of clips = rope diameter x 3 + 1 (round to next whole number)
clip spacing  = rope diameter x 6
turnback = # of clips x spacing
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89
Q

does a single block have mechanical advantage

A

no, it only changes the direction of pull

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90
Q

when a rope connects two blocks together

A

block and tackle

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91
Q

when do you use a snatch block

A

vertical and lateral moves

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92
Q

what hitch would you use to hoist a bundle of steel pipe

A

double-wrap basket hitch

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93
Q

when the throat of a shackle is opened more than __% remove it from service

A

10% (15% by law in canada)

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94
Q

strongest synthetic fibre rope

A

nylon

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95
Q

chain stretch should not exceed _%

A

5%

wear should not exceed 10%

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96
Q

rigging safety factors

A

general lifting = 5:1
lifting people = 10:1
elevators = 20:1

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97
Q

what do you use when wire rope connections are frequently changed

A

wedge sockets

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98
Q

best synthetic rope for shock loads

A

nylon

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99
Q

crane capacity formula

A

(tipping axis/load radius) x crane capacity

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100
Q

this allows you to control the position of the load by friction by wrapping the line around a post or beam

A

snubbed line

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101
Q

When using a shackle to connect to a lifting hook place this part of the shackle on the hook

A

the shackle pin rests on the hook, the sling eyes are on the bow section of shackle

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102
Q

wire core wire rope should not be used at these temps or higher

A

205 C (400 F)

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103
Q

when testing a piece of lifting equipment the point at which it breaks is called it’s

A

breaking strength

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104
Q

SWL of wire rope formula

A

D^2 x 8 = weight in tons

105
Q

when should wire rope be replaced

A

when the surfaces are worn by 1/3 or more of original diameter

106
Q

rigging sheave arc of contact

A

120 to 150 degrees

minimum sheave diameter = 20 times rope diameter

107
Q

how to secure a turnbuckle

A

lock wire

108
Q

scaffold safety factor

A

4 times the load imposed on it

109
Q

at what height are guardrails erected for a temporary platform

A

10 feet

110
Q

at what height are toe boards required when workers can be underneath

A

3.5 meters (11 feet)

111
Q

rule of thumb for outrigger pad floats

A

3 times the area of the pad

ex. 24” diameter pad = .7854 x D^2 x 3

112
Q

which knot is used to lift or lower piping and tubing

A

timber hitch

113
Q

free standing or rolling scaffolding maximum height

A

3 times the smallest footprint

ex. 8’x12’ = 8x3 = 24 feet high

114
Q

procedure for turning off a torch

A

turn off acetylene first

115
Q

how low are foundations set

A

3/4” to 1-1/2” low to allow for grout

116
Q

width of a square key

A

1/4 diameter of the shaft

117
Q

1014 woodruff key =

A 
10/32 = 5/16" wide 
14/8 = 1-3/4" diameter
118
Q

the ability to absorb dirt and abrasives to prevent them from wearing or scoring components in a friction bearing

A

embeddability

119
Q

babbitt pouring temperature is usually this much above the melting temp

A

200 F higher

120
Q

how to mount a taper bore bearing on a cylinder with no shoulder

A

adapter sleeve

121
Q

when should the drive side not be fixed

A

when the weight is on the opposite side and the motor is direct drive with no sheaves to line up

122
Q

which shaft seals can operate at the highest speeds

A

non-contact seals such as labyrinth

123
Q

bearing shield code

A 
Z = shield
RS = seal
124
Q

hydrostatic bearings eliminate this

A

start up wear

125
Q

what type of lubrication supports the rolling elements in the load zone

A

elasto-hydrodynamic film lubrication

126
Q

normal bearing clearance is between these clearances codes

A

C2 - normal - C3

127
Q

the ability of a liquid to maintain contact with a solid surface

A

wettability

128
Q

6210 shaft diameter

A

10 x 5 = 50mm diamater

129
Q

what might cause a lip seal to fail on a shaft

A

shaft run out

130
Q

when connecting a coupling how should the keyways line up

A

180 degrees apart to minimize rotational imbalance

131
Q

which bearing can accommodate displacement and misalignment

A

CARB compact aligning roller bearing

132
Q

best bearing for high speed combined radial/axial loads

A

Angular contact ball bearings

133
Q

which bearing can handle the greatest axial load capacity in both directions

A

four point contact ball bearings

134
Q

key length formula

A

keyway length + coupling width / 2

x 0.95 for accurate length

135
Q

key taper

A

1/8” in 12” or 1:96

136
Q

K taper ratios

A 
K = 1:12
K30 = 1:30
137
Q

amount of material left for reaming

A

below 0.5” hand reamer = 0.001”-0.003”

above 0.5” hand reamer = 0.001”-0.005”

138
Q

cutting speed for steel if not given

A

100 ft/min

139
Q

key width rule of thumb

A

key width is 1/4 the diameter of the shaft

140
Q

key clearances

A

0.002” on the side, 0.005” on the top

141
Q

What should you do with an unmarked liquid container

A

place in a WHIMIS approved cabinet

142
Q

When using an optical level which side do you shim

A

the side that gives you the higher reading (it actually sits lower)

143
Q

What should you do with a damaged safety latch on a post inspection lift

A

tag and repair

144
Q

a worm and wheel reduction unit is showing flakes of metal between the gears what is the cause?

A

lack of EP additive

145
Q

What drill would you use to drill a brass block

A

90 degree angle, dull edge

146
Q

how to make a vertical crane pull a load horizontally

A

snatch block

147
Q

What kind of bolt used on a shackle for a critical lift

A

safety bolt

148
Q

What wire rope resists crushing

A

IWRC

149
Q

proper method to dry a wet sling

A

hang it and let it air dry

150
Q

cylinder acting erratically means

A

bleed air in system

151
Q

how to prevent a cylinder from hitting hard at the end of a stroke

A

adjust cushioning valve

152
Q

what causes aeration in a pump

A

leaking inlet

153
Q

compressor is indicating a higher pressure reading and the temperature is up slightly, what is the cause

A

dirty intake filter

154
Q

a conveyor belt running off in the middle what would be the cause

A

skewed rollers

155
Q

procedure for shortening a conveyor belt

A

un-tension belt, fasten belt (clamp), undo splice, cut, replace splice, re-tension

156
Q

how to measure the pitch of a chain

A

between two pin centres

157
Q

emergency fix for a tear in conveyor belt

A

plate bolt fastener

158
Q

fire extinguisher used on a welder

A

class C

159
Q

What rod to use welding on a high vibration area

A

7018

160
Q

how to check for noise in a bearing

A

stethoscope

161
Q

oil mist lubricators are used in what type of application

A

high speed

162
Q

technique to assess the amount and type of contamination in a system

A

Spectrographic oil analysis

163
Q

how to measure phase angles

A

stroboscopic light

164
Q

where to place lantern ring in stuffing box

A

inline with the fluid

165
Q

levelling baseplate formula

A 
A = T x L2/L1
A = shims required 
T = feel gauge thickness
L1 = length of level
L2 = length of baseplate
166
Q

what allows you to mount a tapered bearing anywhere along the shaft

A

adapter sleeve

167
Q

which bearing has the greatest axial load capacity in both directions

A

four point contact ball bearings

168
Q

where is a manometer installed on a fan

A

on the outlet duct

169
Q

difference between induced and forced draft fans

A

the boiler is cooled by the forced draft fan, sits behind furnace.
in induced draft the pressure in furnace is below atmospheric pressure, sits in front of furnace

170
Q

reasons a diesel engine produces white smoke

A

if white smoke smells like gas it’s exhausting unburnt fuel

if it’s a sweet smell it’s exhausting coolant

171
Q

reasons a diesel engine produces black smoke

A

engine is burning rich, ratio too high in fuel. Clogged air filter or damaged turbo can also cause black smoke

172
Q

when preheating a flame for cutting at what point can you press the oxygen lever

A

when the steel is bright red

173
Q

what process is used to cut ferrous and non ferrous metals

A

plasma arc cutting

174
Q

where do you fix the bearing on a twin screw compressor

A

on the discharge end to maintain the the clearance between the discharge end plate and the screw

175
Q

what bearing is used on the suction end of a twin screw compressor

A

cylindrical roller bearing to allow for axial displacement from thermal expansion (not locked on this side)

176
Q

most common impeller on a single stage centrifugal compressor

A

open impeller

177
Q

when trying to restart a piston compressor but the motor overloads kick out what is the problem

A

malfunctioning unloader valve

178
Q

high levels of compressor oil in the discharge of a two stage compressor what is the problem

A

worn piston rings

179
Q

oil leaking from the intake filter of an oil injected twin screw compressor after shut down what is the problem

A

oil stop valve is stuck open or not sealing

180
Q

two stage piston compressor knocking what is the problem

A

main bearing or connecting rod

181
Q

which screw compressor does not require timing gears

A

oil flooded screw

182
Q

what ensures vane compressors oil circulation through the compressor before air is released into system

A

minimum pressure valve

183
Q

twin screw compressor inlet port vacuum gauge reading slightly higher than normal what is the problem

A

inlet filter is dirty and needs replacement

184
Q

order of installing bearings in a pump

A

check shaft, install bearings, set clearance, assemble pump

185
Q

if a centrifugal pump is rotating in the wrong direction what should you do

A

two of the motor phases should be swapped

186
Q

which impeller has balancing holes

A

semi closed

187
Q

why is a centrifugal pump losing it’s prime when shut down

A

suction line leak, or foot valve

188
Q

when should you start the external flushing system of a centrifugal pump with a mechanical seal

A

before starting the pump

189
Q

calculating thickness of packing

A

subtract shaft diameter from the ID of stuffing box, then divide by 2

190
Q

compressor valves should have the nut facing which way

A

away from the cylinder. always bar over compressor one complete rotation to ensure nothing is hitting

191
Q

a compressor discharge valve always opens ____ the nut, while the suction valve always opens ____ from the nut

A 
discharge = towards
suction = away

when removing valve vent before, and back off not but don’t remove and then tap to jar from seat

192
Q

when an inline piston motor has it’s swashplate adjusted to the greatest angle what happens

A

it will rotate slower with higher torque

193
Q

what are counterbalanced valved set to

A

100-150 psi greater than the load induced pressure from the rod end of the cylinder

194
Q

what would be the cause of a sudden decrease in system hydraulic pressure with a fixed displacement pump

A

stuck pressure relief valve

not a blocked pump because that would affect flow but not pressure

195
Q

what is the purpose of a baffle plate

A

separates contaminants and air from oil before reaching the pump inlet

196
Q

what must be used on a hydraulic motor to prevent it from running away

A

brake valve

197
Q

what can cause air bubbles in a oil reservoir tank even if the oil level is ok and the return line is below the oil surface

A

a loose fitting on the suction side of the pump between the reservoir and pump inlet allowing air to be sucked in (could be a crack or loose fitting)

198
Q

a gearbox seals keep leaking what is the problem

A

plugged breather

199
Q

JIC angle

A

37 degrees

200
Q

what is a -12 hydraulic hose

A

12/16 = 3/4” ID hose

201
Q

type of normally open hydraulic valve

A

pressure reducing

202
Q

on a cold startup the hydraulic pump makes a high-pitched whining and rattling sound what is the problem

A

cavitation

203
Q

what causes water in a hydraulic system

A

condensation in reservoir

204
Q

a cylinder hits hard at the end of an extension stroke what do you do

A

adjust rod end cushion

205
Q

hydraulic shock when the valves change position is causing oil leaks what can you do

A

install an accumulator

206
Q

what do straight pneumatic fittings seal with

A

o-rings or gasket

207
Q

where do you plumb working airlines

A

from the top of the main line to prevent contaminants reaching equipment

208
Q

1 psi = how many kPa

A

6.895

209
Q

what can be used to increase a pneumatic systems pressure

A

intensifier

210
Q

which drying process uses a desiccant and can have their drying media regenerated and reused

A

adsorption (silica gel, two tanks)

211
Q

which air drying process produces a corrosive briny liquid as it dries the air

A

absorption (deliquescent)

212
Q

how do you convert AC to DC

A

bridge rectifier

213
Q

how are NPTF threads sealed

A

thread interference

214
Q

the slope for piping in compressed air systems

A

1 - 2 inches every 10 feet

215
Q

1 psi = how many Hg

A

2.026

216
Q

Pipe anchor procedure

A

Pipe set into the concrete allows bolt inside to move slightly for misalignment
Top opening should be covered with packing waste to prevent concrete from filling up the pipe while foundation is poured
During final grouting, the pipe should also be filled with grout to strengthen anchor bolt and prevent liquids from filling hole and rusting

217
Q

vertical milling set up

A
  • loosen vertical head slightly
  • dial indicator extensions set up in spindle with dial on table surface
  • rotate the dial by hand and adjust head in small increments
  • total runout of 0.001-0.002” required
218
Q

setting up vice

A
  • clamp parallel between jaws so it extends above it entire length of jaw (if no parallel put on fixed jaw)
  • set up dial indicator on flat part of milling machine, adjust dial indicator so plunger rest on front or rear of parallel
  • tighten only one hold down bolt to act as a pivot, second bolt hand tight
  • move table so dial runs length of parallel and use readings to determine which way vice is out of alignment
219
Q

what type of grinding wheel do you use with softer materials

A

a harder wheel

220
Q

how to track a vertical band saw blade

A

the blade should be adjusted to just touch the backup bearing

221
Q

what is the gage of a saw

A

the thickness of the material behind the blade set

222
Q

clearance between a bandsaw blade guide bearing and the blade

A

0.001-0.002”

223
Q

how to break in a new bandsaw blade

A
  • begin cut with reduced feed rate (20-40% of normal)
  • once cut has begun increase feed rate 10%
  • gradually increase until normal rate achieved
224
Q

how do you sharpen a chisel on a grinding wheel

A

cutting edge of chisel applied PARALLEL to the axis of the grinding wheel

225
Q

how many saw teeth in contact with a workpiece minimum

A

3

226
Q

minimum overlap of wood planks between bays on scaffolding

A

12”

227
Q

strength of a explosive actuated tool cartridge identified by

A

power load number and colour

228
Q

drill used to start a hole in workpiece

A

spotting drill/centre drill

229
Q

which quenching medium cools materials the fastest

A

brine, followed by water

230
Q

UNF meaning

A

unified fine thread

231
Q

pipe taper per foot

A

3/4”

232
Q

how do you hook up a brake valve for hydraulic motor

A

external pilot connected to inlet, internal pilot to motor outlet

233
Q

operating radius of a crane

A

the centre rotation of the crane to the centre of gravity of the load

234
Q

crane capacity formula

A

((tipping axis / load radius) x crane capacity) x efficiency rating

235
Q

mechanically clipped eye with thimble rating

A

80%

236
Q

cutting speed formula

A

rpm = (CS x 4) / diameter of drill

measured in surface feet per minute

237
Q

tap drill size formula

A

TDS = major diameter - (1 / TPI)

238
Q

when tapping a hole how often do you reverse the tap

A

every one half turn

239
Q

arc of contact for wire rope on sheaves

A

120 - 150 degrees

minimum pulley diameter 20 times diameter of rope

240
Q

a hydraulic cylinder with a piston leak is extending and the pump delivers enough flow to exceed leakage, what happens?

A

it extends slower but with the same force

241
Q

where do you install a kiss idler

A

a flat pulley that just touches the belt on the slack side of the drive.
must be 1.5 times the diameter of the sheave
they do NOT increase arc of contact

242
Q

on a roller chain drive the what is the sprocket ratio to maintain the minimum arc of contact

A

3:1

243
Q

v-belt outside idlers should be how big

A

1.5 times the smaller (drive) sheave

244
Q

worn sides along the whole length of the v-belt what is the problem

A

sheave misalignment

245
Q

v-belt squealing is a symptom of what

A

shock loading

246
Q

hardening or glazing on the sides of a v-belt indicate what

A

belt slippage

247
Q

frequency X rpms

A 
unbalance 1 x rpm
misalignment 2 x rpm
looseness 2 x rpm
belt drive 3 x rpm 
bearing failure multiple x rpm
248
Q

when moving an accelerometer from vertical to horizontal and there is a 90 degree phase shift what is the vibration caused by

A

imbalance

249
Q

angular misalignment shim formula

A 
D = diameter of coupling
A = distance from coupling to back foot
B = distance from coupling to front foot

(A / D) x feeler calculation = back shim change
(B / D) x feeler calculation = front shim change

250
Q

what is used on air hoses over 1/2 inch

A

excess flow/stop valve

251
Q

you are testing a motor and find high ohm resistance what does this mean

A

open circuit

252
Q

what do you do to change the amount of oil used in an oil mister

A

change air pressure

253
Q

a new chemical arrives on site what do you look for

A

MSDS

254
Q

you welded a pipe and need to cool it down to reduce stress what is this called

A

annealing

255
Q

how to store safety harness

A

hang by D ring in a dry clean place

256
Q

why do you re-torque a cylinder head after a run-in period

A

vibration and pressure will cause the cylinder head bolts to stretch and other components to seat

257
Q

working drawings are usually done in

A

orthographic projection

258
Q

what unit are fans measured in

A

inches of water (manomater)

IP Notes (1 decks)

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